Flexible film container and manufacturing method

ABSTRACT

A self-supporting flexible film container is disclosed that includes a container base and a flexible film attached to the container base that forms a container wall and defines a packing region within the container. The container wall has at least one support column, such as a tubular support column, integrally formed therein. A method of conforming the container includes providing a web of flexible film, forming tubular support columns in the web of flexible film and forming a container from the web of flexible film containing the support columns. The support columns can be formed by ploughing and forming the web of flexible film.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority to and the benefit of U.S. App. No.61/993,321 filed May 15, 2014 which is hereby incorporated by referencein its entirety.

FIELD

This application is directed to flexible film containers and processesof manufacturing that include using flexible films. More particularly,this application relates to flexible films and containers having supportcolumns and processes for manufacturing such flexible films andcontainers.

BACKGROUND

Candy and other small or bite-size products like nuts, savory snacks,frozen heat-n-eat snacks, frozen heat-n-eat vegetables, ready-to-eatcereal, and mints are typically sold in multi-piece packages. In manycases, the package is designed for bulk sale of the product to theconsumer rather than as a single serving size, although in some casesthe individual product may still be separately wrapped prior to beingplaced in the package.

Historically, the packaging of multi-piece units, particularly forcandy, was primarily accomplished through the use of paper bags or metaltins. More recently, plastic bags, and more particularly the plastic bagoften referred to as a pillow pack or a lay-down bag has become theindustry standard. While pillow packs are advantageous because they arerelatively easy and inexpensive to manufacture, they have numerousdrawbacks for both the retailer and the consumer.

Among the drawbacks faced by the retailer with pillow packs is that theyare difficult to stack in a way that does not easily fall over in aretail setting where consumers are reaching in and out of shelves.Similar issues apply to gusseted bags and stand-up bags. As a result, itcan be difficult for the retailer to present the product in a way thatdoes not look disheveled and/or which does not require frequentattention by the retailer's staff. Furthermore, the portion most easilyseen by the consumer can be narrow sides; the major surfaces of thepackage that provide the greatest area for graphics face toward the topof the shelf or being aligned to face away from a consumer. The reducedspace for advertisements and branding can mean a lost opportunity toachieve a sale through brand recognition or a promotion advertised onthe package. Likewise, the consumer must look more carefully to find hisor her brand of choice on the store shelf, and may give up if theproduct cannot be found quickly.

Among drawbacks faced by consumers with current packs is that theconsumer faces many of the same problems regarding stackability andstorage of the product on the pantry shelf that the retailer encounterswith the store shelf. Other disadvantages faced by the consumer with thepacks currently used for packaging include difficulty in opening thepackage and additional storage problems after the package is opened.

A known process includes making containers that include pleats, whichare folds in a film. Including pleats on the interior portions of acontainer with walls formed by a flexible film can increase strengthand/or permit better display of packages than pillow packs. However,further improvements to strength and ability to display packages remaindesirable, for example, to permit higher stacking of containers, topermit heavier contents to be placed in containers, and/or for largerwalls capable of displaying more information.

Improvements in flexible films, containers formed from flexible films,and processes of manufacturing that include using flexible films, incomparison to the prior art would be desirable.

Other features and advantages of the present invention will be apparentfrom the following more detailed description, taken in conjunction withthe accompanying drawings which illustrate, by way of example, theprinciples of the invention.

BRIEF DESCRIPTION OF THE INVENTION

According to an embodiment, a container comprises a container base and aflexible film attached to the container base forming a container walland defining a packing region within the container. The container wallhas at least one tubular support column integrally formed therein.

According to another embodiment, a manufacturing process comprisesproviding a web of flexible film, forming tubular support columns in theweb of flexible film and forming a container from the web of flexiblefilm containing the support columns.

According to yet other embodiments, films, processes, and containersinclude that which is shown and described herein.

Advantages that may be achieved with exemplary embodiments includeproviding films and containers that contain additional strength and/orrigidity, permit lower cost production of containers, permit increasedvisibility of graphics or other identifiable information on packaging,permit easier and quicker restocking in retail settings, permit easierand less costly transportation, and provide other advantages that willbe evident from the present disclosure, or a combination thereof. Otherfeatures and advantages of the present invention will be apparent fromthe following more detailed description, taken in conjunction with theaccompanying drawings which illustrate, by way of example, theprinciples of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a perspective view of an embodiment of a flexible filmwithin a film sheet having support columns for extending throughout thefilm sheet, according to the disclosure.

FIG. 2 shows a perspective view of an embodiment of a flexible filmhaving support columns, according to the disclosure.

FIG. 3 shows a schematic view of an embodiment of a flexible film havingsupport columns, according to the disclosure.

FIG. 4 shows a perspective view of an embodiment of a container formedfrom a flexible film having support columns, according to thedisclosure.

FIGS. 5-6 show perspective views of an embodiment of a container havinga handle, according to the disclosure.

FIGS. 7-8 show perspective views of an embodiment of a container havingpull-tabs, according to the disclosure.

FIG. 9 shows a perspective view of a container cover having a bendablejoint for an embodiment of a container, according to the disclosure.

FIG. 10 shows a perspective view of a container cover havingexternally-protruding pull tabs for an embodiment of a container,according to the disclosure.

FIG. 11 shows a perspective view of a container cover having a two-piecearrangement of a lower rectangular recessed portion and an uppersubstantially planar rectangular portion for an embodiment of acontainer, according to the disclosure.

FIG. 12 shows a perspective view of a container cover having a two-piecearrangement of a lower rectangular open portion and an upper rectangularsubstantially planar portion for an embodiment of a container, accordingto the disclosure.

FIG. 13 shows a perspective view of a container cover having a two-piecearrangement of a lower circular open portion and an upper circularsubstantially planar portion for an embodiment of a container, accordingto the disclosure.

FIG. 14 shows a container cover having a flap for an embodiment of acontainer, according to the disclosure.

FIG. 15 shows an embodiment of a container with a container base andcontainer cover positioned horizontally relative to a flexible film,according to the disclosure.

FIGS. 16-19 show perspective views of stacked containers, according toan embodiment of the disclosure.

FIG. 20 pictorially depicts an embodiment of a manufacturing process,according to the disclosure.

FIG. 21 shows a perspective view of a roll connected to a web-tensioningmechanism that leads to a web steering system for use in an embodimentof a manufacturing process, according to the disclosure.

FIG. 22 shows a perspective view of a first web guide, a column formingmechanism, and a second web guide for use in an embodiment of amanufacturing process, according to the disclosure.

FIG. 23 shows a perspective view of a column forming mechanism for usein an embodiment of a manufacturing process, according to thedisclosure.

FIG. 24 shows a perspective view of a web spreading mechanism for use inan embodiment of a manufacturing process, according to the disclosure.

FIG. 25 shows a section of a flexible film sheet having a support columnwith a second portion and a first portion on opposite sides of acenterline through the flexible film, according to an embodiment of thedisclosure.

FIG. 26 shows a perspective view of a column flattening mechanism foruse in an embodiment of a manufacturing process, according to thedisclosure.

FIG. 27 shows a perspective view of a tension maintaining device for usein an embodiment of a manufacturing process, according to thedisclosure.

FIG. 28 shows a perspective view of a device that includes a firsttransformation mechanism, a tube welder, a second transformationmechanism, and a cutting mechanism for use in an embodiment of amanufacturing process, according to the disclosure.

FIG. 29 shows a perspective view of a welding system for use in anembodiment of a manufacturing process, according to the disclosure.

FIG. 30 shows a perspective view of a rotating weld head for use in anembodiment of a manufacturing process, according to the disclosure.

FIG. 31 shows a perspective view of an expanding corner anvil head foruse in an embodiment of a manufacturing process, according to thedisclosure.

FIG. 32 shows a perspective view of a nesting system for use in anembodiment of a manufacturing process, according to the disclosure.

FIG. 33 shows a diagrammatic view of loading of an embodiment of acontainer, according to the disclosure.

FIG. 34 illustrates a partial cross-sectional view of the column formingmechanism of FIG. 23.

FIG. 35 illustrates a support column in accordance with anotherexemplary embodiment of the disclosure.

Wherever possible, the same reference numbers will be used throughoutthe drawings to represent the same parts.

DETAILED DESCRIPTION OF THE INVENTION

Provided are a flexible film, a container, and a manufacturing process.Embodiments of the present disclosure, for example, in comparison tosimilar concepts failing to include one or more of the featuresdisclosed herein, provide additional strength and/or rigidity, permitlower cost production of containers, permit increased visibility ofgraphics or other identifiable information on packaging, permit easierand quicker restocking in retail settings, permit easier and less costlytransportation, provide other advantages that will be evident from thepresent disclosure, or a combination thereof.

FIG. 1 shows an embodiment of a flexible film 101. The flexible film 101is shown within a film sheet 100 having a plurality of the flexiblefilms 101 adjacently arranged for the manufacturing process, prior tocutting the plurality of the flexible films 101 to produce discretearrangements of the flexible films 101. The flexible film 101 permitsincreased strength, increased stackability, and easier display on acontainer 401 (see FIG. 4) including the flexible film 101. As shown inFIGS. 1-4, the flexible film 101 includes wall portions 103 in aflexible film material 105 that are separated by support columns 107 inthe flexible film material 105, the support columns being formed fromthe same web of flexible film as the container wall and thus beingformed integral therewith. While primarily shown and described withrespect to tubular support columns 107, it will be appreciated that theinvention is not so limited and that the support columns 107 may beformed in any suitable manner, including, for example, one or morez-folds as illustrated in FIG. 35 and discussed subsequently herein.

The flexible film material 105 is any material that is generally capableof being used for packaging, with a general preference for two sidesealable films. The container 401, the flexible film 101, and/or thefilm sheet 100 include materials that are microwaveable or are notsuitable for microwaving and that contain vents for the release ofpressure or do not contain vents for the release of pressure. Suitablematerials include, but are not limited to, a single or multiple layerfilm, composite, or laminate, for example, including ethylene vinylalcohol copolymer, polyamide, polyacrylonitrile, polyethyleneterephthalate (PET), polyalkene (polyolefin), polyethylene,polypropylene, polylactic acid (PLA), cellophane, bioplastic-based film,any suitable polymer, or a combination thereof as well as metalizedfilm, paper, or any other materials or laminates employing suchmaterials. In one embodiment, the film comprises an oriented and/or castpolypropylene (OPP and CPP, respectively).

Among the factors in film selection for a particular embodiment, asidefrom properties for containing a particular type of food, are those thatimpact the manufacture of the packaging, such as film stiffness. Filmsthat are too stiff can result in large tension variations across a webof film during manufacture, as well as result in friction that canresult in delamination or breakage. The flexible films 101 typicallyused in exemplary embodiments have a Gurley stiffness in the range of 80to 140 mg (as measured using a standard Gurley-type stiffness tester).Film thickness to achieve the desired stiffness may vary depending uponthe particular composition(s) of the flexible film material, but canrange, by way of example, up to about 100 microns or greater.

Any suitable number of the support columns 107 providing desiredstrength is capable of being used. For example, in various embodimentsof the flexible film 101, three, four, five, or six of the supportcolumns 107 are included in the flexible film 101. In one embodiment,the support columns 107 are ultrasonically welded into form during theproduction of the film sheet 100, for example, providing the increasedstrength for the container 401, permitting the flexible film 101 to beself-supported, with or without rigid supports being positioned in thecontainer 401 and/or the flexible film 101. While one of the advantagesof exemplary embodiments is the ability to provide a self-supportedcontainer without the use of rigid supports, they are not necessarilyexcluded and may be used in combination with the support columns 107.Exemplary embodiments achieve a force load measurement—without relyingon container contents and/or rigid supports—that is two to eight timesstronger than conventional flexible packages.

Additionally or alternatively, the support columns 107 are formed duringthe production of the film sheet 100 by adhesive, mechanical techniques,ultrasonic welding, cold seal, hot seal, or any other suitable techniqueof welding two or more surfaces to another. Additionally oralternatively, in one embodiment, the support columns 107 enclose a gas(such as, air or an inert gas), for example, providing the increasedstrength for the container 401, permitting the flexible film 101 to beself-supported, with or without rigid supports being positioned in thecontainer 401 and/or the flexible film 101.

While primarily discussed herein as containing a gas, it will beappreciated that the invention is not so limited and that any fluidmaterial (i.e., any flowable matter) may be contained within the supportcolumns 107, including a liquid, fine powder, etc. In some embodiments,for example, it may be desirable to fill one or more of the supportcolumns 107 itself with a food item such that the support column acts asa package within a package to separate contents within the container401, such as nuts and candy or chips and dip, for example. As a result,exemplary embodiments permit a single web of flexible film to be used inmaking a multi-compartment container.

To maintain tension, reduce friction, and result in a gradual narrowingof the film sheet 100, in one embodiment, the support columns 107 areproduced in a staggered, sequential, or periodic manner. For example, inan embodiment, with four of the support columns 107, one or two of thesupport columns 107 are formed at a time. The support columns 107 areformed while the film sheet 100 is static or as it moves.

In the embodiment shown in FIG. 1, the flexible film 101 includes thesupport columns 107 enclosing the gas. The support columns 107 enclosethe gas between flattened regions 109, for example, positioned along adirection 111 for cutting the film sheet 100 to discrete arrangements ofthe flexible film 101, which are capable of being used to produce thecontainer 401. FIGS. 2 and 3 show embodiments of the flexible film 101as such discrete arrangements capable of being used to produce thecontainer 401. It will be appreciated that for embodiments which use oneor more support columns 107 to also used as a storage area to contain afood or other item, that the support column to be filled is typicallynot permanently flattened during processing and at least one end is leftunsealed to allow later filling. It will further be appreciated that thesize of a column that is to subsequently be filled with a product to beconsumed may be different (typically larger) than those used primarilyto impart strength to the container 401.

As shown in FIG. 2, in one embodiment, the support columns 107 arearranged within the flexible film 101, and the wall portions 103 abuteach side of the support columns 107. In this embodiment, two of thewall portions 103 are capable of overlapping and/or being fused togetherto wrap the flexible film 101 in a continuous manner as is shown in FIG.4 to form the sidewall of the container 401. Among the advantages ofexemplary embodiments is that the support columns 107, formed integralfrom the same web of film 101 used to form the container wall portions103, can each be formed on the same side of the web. Thus, when wrappedand sealed to form the continuous container wall, the support columns107, and any associated seams and/or welds from their formation, arehidden from view within the interior of the container 401. As a result,an essentially continuous printable surface is provided on the exteriorof the container 401 for presenting graphics or other text or brandingwithout multiple visible seals or seams that could otherwise interruptand/or make printing graphics (or aligning pre-printed graphics) moredifficult, with only the single seam joining the two ends of the filmvisible on the exterior of the container 401.

As shown in FIG. 3, the support columns 107 have a support column width301 that is smaller than a wall portion width 303 for the wall portions103 and a film length 305 for the flexible film 101. Suitable values forthe support column width 301 include, but are not limited to, being lessthan 50 millimeters, being less than 40 millimeters, being less than 30millimeters, being between 20 and 30 millimeters, or any suitablecombination, sub-combination, range, or sub-range therein. Suitablevalues for the film length 305 range include, but are not limited tobeing greater than 100 mm, being less than 1000 mm, being between 100and 1000 mm, such as 200, 300, 400, 500, 600, 700, 800, or 900 mm or anysuitable combination, sub-combination, range, or sub-range therein.

Suitable values for the wall portion width 303 include, but are notlimited to, being greater than 50 millimeters, being less than 200millimeters, being between 50 and 200 millimeters, such as 60, 70, 80,90, 100, 110, 120, 130, 140, 150, 160, 170, 180, or 190 mm or anysuitable combination, sub-combination, range, or sub-range therein. Inone embodiment, the relative value of the wall portion width 303 incomparison to the support column width 301 is at a ratio, for example,of 10 to 1, 9 to 1, 8 to 1, 7 to 1, 6 to 1, 5 to 1, 4 to 1, 3 to 1, 2 to1, 1 to 1, or any suitable combination, sub-combination, range, orsub-range therein.

Suitable values for the column length 307 (also generally correspondingto container height) include, but are not limited to, being greater than50 millimeters, being less than 200 millimeters, being between 50 and200 millimeters, such as 60, 70, 80, 90, 100, 110, 120, 130, 140, 150,160, 170, 180, or 190 mm, or any suitable combination, sub-combination,range, or sub-range therein. In one embodiment, the relative value ofthe film length 305 in comparison to the support column width 301 is ata ratio, for example, of 10 to 1, 9 to 1, 8 to 1, 7 to 1, 6 to 1, 5 to1, 4 to 1, 3 to 1, 2 to 1, 1 to 1, or any suitable combination,sub-combination, range, or sub-range therein.

Referring to FIG. 4, the container 401 formed from the flexible film 101includes the flexible film 101 affixed to a container base 403, forexample, by heat welding and/or ultrasonic welding, to define a packingregion 405 within the container 401. The packing region 405 is anysuitable geometry capable of being formed with the flexible film 101having the support columns 107 (for example, in corners 407 of thecontainer 401) and the wall portions 103. Suitable geometries, include,but are not limited to, generally having a sectional profile of atriangle, a square, a rectangle, a pentagon, a hexagon, or any otherpolygon, although it will be appreciated that exemplary embodiments alsoinclude geometries with rounded sides, such as cylindrical (both roundand ovular, for example). Although the container 401 shown in FIG. 4includes the section profile being the square, the size of the wallportions 103 and/or the support columns 107 are capable of being variedto produce a complex-shaped embodiment of the container 401. The packingregion 405 is capable of being used for storing any collection of smallarticles such as food (for example, candy, nuts, mints, and/or pasta),spices, seeds/bulbs, or fasteners, all by way of example.

The container base 403 corresponds to the desired geometry for thecontainer 401. FIG. 4 shows the container base 403 corresponding toembodiments of the container 401 generally having the sectional profileof the square. The container base 403 shown is a strengthened basehaving a strength-enhancing design, for example, a rigid thermoplastichaving a pre-determined defined shape such as those produced duringcold-forming, thermoforming, or a combination thereof. In otherembodiments, the container base 403 is a flexible film that is formed toa pre-determined defined shape, such as just mentioned with respect torigid thermoplastics and/or which is formed into its shape as part ofcontainer manufacturing operations. The container base 403 may beconfigured either in advance or during container manufacturing such thata surface portion of the container base 403 is in a parallel plane witha portion of the container wall portions 103 to create a sealable edge(as shown, for example, in FIG. 33).

In one embodiment, the strength-enhancing design and/or the containerbase 403 in general decrease(s) the amount of deformation within thewall portions 103 during stacking of the containers 401. Other suitablefeatures capable of being included in the container base 403 to providestrength include, but are not limited to, raised edges 411 or chamfersfor nesting and/or stacking containers 401 on top of one other. Inembodiments in which the container base 403 is itself formed of aflexible film material, that material may be of the same or a differentmaterial from that used to form the side walls of the container 401.

In addition to the container base 403 being affixed to the flexible film101, in one embodiment, a container cover 409 is affixed to the flexiblefilm 101 to form the container 401. The container cover 409 is affixedto the flexible film 101 by ultrasonic welding, adhesive, mechanicaltechniques, cold seal, hot seal, or any other suitable technique.

The container cover 409 is any suitable design meeting the desired enduse, such as, but not limited to, being microwavable, havinginstructions for use, being sealed, being re-sealable, allowing hotgases to vent, allowing pouring, and/or having heating/cooling packsand/or insulation. For example, in one embodiment, as shown in FIG. 4,the container cover 409 is substantially planar and rigid. In oneembodiment, as shown in FIGS. 5-6, the container cover 409 includes ahandle 501 and vent holes 601 exposed by repositioning the handle 501 ina direction 603 from the orientation in FIG. 5 to the orientation inFIG. 6. In some embodiments, the vent holes 601 (see FIG. 6) may insteadbe formed as a plurality of small holes or other punctures in the cover409 that may be sized to allow some pressurization when the container'scontents are heated (for example during microwaving of a container 401containing a food product), which in some embodiments is accomplished bythe vent holes 601 being configured to achieve a vent pressure of 0.5psig or less.

In another embodiment, as shown in FIGS. 7-8, the container cover 409includes pull-tabs 701 capable of opening and/or tearing a portion 801of the container cover 409 when pulled in a direction 703 from theposition in FIG. 7 to the position in FIG. 8. Other embodiments include,but are not limited to, the container cover 409 having a bendable joint901 positioned substantially in the center of the container cover 409(see FIG. 9), having externally-protruding pull tabs 1001 that extendbeyond the profile of the container cover 409 upon being adjusted (seeFIG. 10), having a two-piece arrangement of a lower rectangular recessedportion 1101 and an upper substantially planar rectangular portion 1103configured to be secured within the lower rectangular recessed portion1101 (see FIG. 11), having a two-piece arrangement of a lowerrectangular open portion 1201 and an upper rectangular substantiallyplanar portion 1203 configured to cover an open rectangular portion 1205of the lower rectangular open portion 1201 upon being secured to thelower rectangular open portion 1201 (see FIG. 12), having a two-piecearrangement of a lower open portion 1301 and an upper circularsubstantially planar portion 1303 configured to cover an open circularportion 1305 of the lower open portion 1301 upon being secured to thelower open portion 1301 (see FIG. 13), the container cover 409 having aflap 1401 or pealable portion capable of being opened upon bending atedge 1403 or otherwise ripping/tearing of the container cover 409 (seeFIG. 14), a feature within the container cover 409 being arranged as orin conjunction with a vent, or a combination thereof.

As will be appreciated, the container base 403 and/or the containercover 409 are capable of being arranged in any orientation with respectto the flexible film 101. For example, as shown in FIG. 15, in oneembodiment, the container base 403 and the container cover 409 arepositioned horizontally relative to the flexible film 101, with the termhorizontal representing a direction perpendicular or substantiallyperpendicular to the direction of gravity. In a further embodiment, thecontainer cover 409 includes a seal portion 1501 and a cover portion1503 for covering the seal portion 1501, the cover portion 1503 having aremovable region 1505 or spout, allowing access to the seal portion1501, which is capable of being punctured to allow fluid contents toexit the container 401.

Referring to FIG. 16, the containers 401 are capable of being stackedwith or without other structures, such as trays or cartons, with thecontainers 401 in some embodiments being stacked in a nestable fashion,with the base 403 of one container 401 being nested by the cover 409 ofa second container on which it is stacked. In the illustratedembodiment, one or more stacks 1601 of the containers 401 is/arepositioned within a tray 1603, such as a corrugated and/or die cutmaterial. In a further embodiment, the stacks 1601 are positionedadjacent and within recesses 1605 having a die cut 1609 and geometrycorresponding with the container base 403 for each of the containers 401positioned on the bottom of the stacks 1601. The stacks 1601 are capableof including any suitable number of the containers 401, for example, twoof the containers 401, three of the containers 401, four of thecontainers 401, or more of the containers 401, so long as the containers401 positioned on the bottom of the stacks 1601 are not crushed ordamaged by the containers positioned above them. In one embodiment, acovering 1607, such as a card hood, is capable of being positioned onthe stacks 1601, thereby enclosing them in conjunction with the tray1603, providing protection (for example, from debris, damage,early-display, or a combination thereof), providing a displayarrangement that decreases the duration of time for replenishment,providing simpler transportation and/or storage, providing increasedfreshness of contents, or a combination thereof.

Referring to FIGS. 17 through 19, in one embodiment, the stacks 1601 arewrapped with a collation wrap 1701 to provide structural support withinthe stacks 1601 and/or to prevent damage to the containers 401. Thecollation wrap 1701 reduces or eliminates movement and/or damage of thecontainers 401 by securing them together. The collation wrap 1701 iscapable of extending around one of the stacks 1601 or a plurality of thestacks 1601 and/or is capable of being wrapped with a film wrap 1703. Inone embodiment, as shown in FIGS. 18 and 19, the film wrap 1703 includesa lip 1801 for retaining the stacks 1601 within the collation wrap 1701inside of the film wrap 1703. As shown in FIG. 19, in one embodiment,the lip 1801 is capable of being folded to open or close an accessregion 1901 for accessing the stacks 1601 and/or the containers 401.

FIG. 20 shows an embodiment of a manufacturing process 2000 forproducing the flexible film 101 and/or the container 401. The flexiblefilm 101 is formed by forming the support columns 107 (step 2002) andforming the wall portions 103 (step 2004). The container 401 is formedby attaching the container base 403 (step 2006) and, in a furtherembodiment, attaching the container cover 409 (step 2008).

Referring to FIG. 21, in one embodiment, the forming of the supportcolumns 107 (step 2002) includes unwinding a roll 2102 connected to aweb-tensioning mechanism 2103 that leads to a web steering system 2105to produce the film sheet 100. In a further embodiment, the unwindingfurther includes splicing of the film sheet, for example, with anautomatic splicing system. In some embodiments, a turner bar may beemployed to flip the film sheet, isolating a bow wave formed in the webby column forming from the steering system. This can help overcomemisalignments between unwinding of the film and the column formation, aswell as helping to overcome tracking effects of column formation.

Referring to FIG. 22, in one embodiment, the forming of the supportcolumns 107 (step 2002) includes the film sheet 100 entering a first webguide 2201, prior to the film sheet 100 travelling to a column formingmechanism 2203 that produces the support columns 107 in the film sheet100 after exiting a second web guide 2201. In a further embodiment, thefilm sheet 100 then travels through a web spreading mechanism 2205 and acolumn flattening mechanism 2207, where the support columns 107 areflattened. In one embodiment, the forming of the support columns 107(step 2002) is adjustably controlled by a hitch fixed clamp 2209, ahitch index 2211, and a hitch moving clamp 2213.

As shown in FIG. 23, in one embodiment, the column forming mechanism2203 ploughs/forms and seams/welds the flexible film material 105 in thefilm sheet 100 to produce the tubular support columns 107 integral withthe web, thereby laterally defining the wall portions 103. The formingincludes guiding the film sheet 100 through the column forming mechanism2203, integration and seaming by the column forming mechanism 2203,inflation of the support column 107 (for example, with compressed air,ambient/entrained air, or another suitable inert gas to increase thestructural integrity of the support column 107) by the column formingmechanism 2203, or a combination thereof. FIG. 34 illustrates a partialcross-sectional view of the column forming mechanism 2203 including aploughing tool 3401, plough mandrel 3407 and weld tool 3403. As shown,the plough mandrel has an interior chamber that provides a gas inflationchannel 3405 for embodiments in which air or another gas is optionallyintroduced into the column 107 during formation.

The column forming mechanism 2203 moves relative to the web of flexiblefilm material 105 which may be accomplished either by continuous flow ofthe web through the mechanism or, more typically, incremental movementof the web, followed by movement of the column forming mechanism 2203relative to the web while the web remains temporarily stationary.

As shown in FIG. 24, in one embodiment, the web spreading mechanism 2205spreads the film sheet 100 after the column forming mechanismploughs/forms and seams/welds the flexible film material 105 in the filmsheet 100 to produce the support columns 107. The web spreadingmechanism 2205 spreads the film sheet 100 to align the support columns107 for flattening. For example, referring to FIG. 25, in oneembodiment, a first portion 2501 of the support column 107 and a secondportion 2503 of the support column 107 are aligned such that each of thefirst portion 2501 and the second portion 2503 are on opposite sides ofa centerline 2505 that is perpendicular, or substantially perpendicular,to the film sheet 100. In a further embodiment, the first portion 2501has a first volume that is within a selected relative range of a secondvolume of the second portion 2503, for example, the first volume beingwithin 20% of the second volume, the first volume being within 10% ofthe second volume, the first volume being within 8% of the secondvolume, within 5% of the second volume, the first volume being within 3%of the second volume, being within 1% of the second volume, or anysuitable combination, sub-combination, range, or sub-range therein. Thatis, the support column 107 is preferably flattened evenly so that thereis an equal or approximately equal amount of the material forming thesupport column 107 on both sides of the centerline 2505.

As shown in FIG. 26, in one embodiment, the column flattening mechanism2207 applies pressure to one or more of the support columns 107 in thefilm sheet 100, for example, on both the first portion 2501 and thesecond portion 2503 of the support columns 107. The pressure adjusts thegeometry of at least a portion of the support columns 107, for example,from having a circular profile to a rectangular profile. Flattening inconjunction with a lower volume variation of the first volume and thesecond volume provides additional strength in comparison to flatteningwith a higher volume variation. In one embodiment, ends of the supportcolumns 107 are sealed by the flattening, thereby defining a regionwhere the support columns 107 are capable of being cut without allowingthe gas to escape from within the support columns 107. In anotherembodiment, the entire support column 107 is flattened, either partiallyor entirely, with entrained air able to escape by sealing one end of thesupport column 107 followed by sealing the opposite end afterflattening.

In still another embodiment of the invention, illustrated in FIG. 35,the support column 107 is formed as a series of overlapping folds 3503,such as one or more z-folds. In this embodiment, rather than forming atube, the plowing and forming step includes one or more additional foldsin the web to form the support column 107. Depending on the number offolds and/or the order and direction of sealing operations, gas may ormay not still be trapped within the support column 107. In someembodiments in which the support column 107 is a folded column, thesupport column 107 is entirely flattened and then welded over its fullwidth and/or length.

As shown in FIG. 27, in one embodiment, the forming of the wall portions103 (step 2004) includes use of a tension maintaining device 2701. Inone embodiment, the tension maintaining device has a receiving roller2703 for receiving the film sheet 100, a dancing arm 2705 positioned toreceive the film sheet 100 from the receiving roller 2703 and tomaintain tension of the film sheet 100 despite adjustments in the rateof movement after the tension maintaining device 2701, and a roller 2707positioned proximal to a guide roller 2709, where the film sheet exitsthe tension maintaining device 2701. The rollers are any suitablegeometry capable of supporting the film sheet 100. The rollers aretriangular, square, pentagonal, hexagonal, or any other suitablegeometry. In one embodiment, the rollers have planar portions 2711 ofequal or slightly smaller size than the wall portions 103 and cornerportions 2713 separating the planar portions 2711. In one embodiment,the rollers are designed to accommodate a change in direction of thefilm sheet 100, for example, while prohibiting bending within thesupport columns 107.

As shown in FIG. 28, in one embodiment, the forming of the wall portions103 (step 2004) is achieved by a device 2800 that includes a firsttransformation mechanism 2801 (for example, to transform the film sheet100 from planar to round), a tube welder 2803 (for example, to weld thefilm sheet 100 from the round geometry into a tube), a secondtransformation mechanism 2805 (for example, to transform the film sheet100 from being round to being square or another suitable geometry forthe flexible film 101), and a cutting mechanism 2807 used for cuttingthe film sheet 100 into discrete units of the flexible film 101 capableof being used to form the container 401, for example, in a circularfashion around the perimeter of the flexible film 101. Cutting of thepolygonal perimeter in a circular or arc like fashion results in thecutting occurring with a slicing action in contrast to stabbing orsquare pecking found in conventional cutting operations. In a furtherembodiment, the movement of the film sheet 100 through the device 2800is performed by an urging force applied by a tube drive 2809, forexample, positioned between the second transformation mechanism 2805 andthe cutting mechanism 2807. In one embodiment, one or more of thecomponents of the device 2800 are held under vacuum to provideadditional stability for the film sheet 100 during the transformation,welding, and/or cutting.

Forming of the container 401 from the flexible film 101 begins with theattaching of the container base 403 (step 2006) or the attaching of thecontainer cover 409 (step 2008) to one or more of the wall portions 103of the flexible film 101, for example, using a welding system 2901 as isshown in FIG. 29. An embodiment of the welding system 2901 includes anesting system 2903 (see FIG. 32) for receiving the wall portion(s) 103and an insertion head 2905 for receiving the container base 403 and/orthe container cover 409. The nesting system 2903 is a precision-machinedpart providing location accuracy, having a vacuum plenum 3201 capable oftemporarily holding the wall portion(s) 103 (for example, duringre-referencing), and having interchangeable geometry-defining elements3203, permitting use with different sized-parts.

The container base 403 and/or the container cover 409 are welded to thewall portion(s) 103 by any suitable technique. Suitable techniquesinclude, but are not limited to, being ultrasonically welded and/orbeing heat-welded. In one embodiment, the welding begins with a tackweld to hold the container base 403 or the container cover 409 inposition and is followed by a finish weld for complete attachment to beachieved. The welding is achieved by using any suitable devices, suchas, rotating weld heads 2907 (see FIG. 30), an expanding corner anvilhead 2909 (see FIG. 31), and/or an energy chain tray 2911. The rotatingweld heads 2907 have a tool geometry configured to the desiredend-product, such as the container 401. The expanding corner anvil head2909 is an expanding mechanism configured to stretch out the flexiblefilm 101 during the welding, for example, by being pre-heated to reducewelding times.

Referring to FIG. 33, in one embodiment, after the positioning of thewall portions 103 and the attaching of the container base 403 within thenesting system 2903, the packing region 405 is loaded with a product3301 prior to the attaching of the container cover 409 and thecompletion of the container 401. In this embodiment, the container base403 is shown as a sheet of flexible film that is pushed through whatwill become the top of the container and then sealed at its edges, thesheet used for the container base being wider than the space defined bythe wall portions 103, leaving selvedge that folds against the innerwall that forms an overlapping surface for sealing. Alternatively, thecontainer cover 409 is attached prior to the loading of the product 3301and the container base 403 is attached afterward. In either case, insome embodiments in may be desirable to introduce air or another gas(such as nitrogen in the case of most food products) to fill head spaceover the container contents and optionally to pressurize the container401.

While the invention has been described with reference to one or moreembodiment, it will be understood by those skilled in the art thatvarious changes may be made and equivalents may be substituted forelements thereof without departing from the scope of the invention. Inaddition, many modifications may be made to adapt a particular situationor material to the teachings of the invention without departing from theessential scope thereof. Therefore, it is intended that the inventionnot be limited to the particular embodiment disclosed as the best modecontemplated for carrying out this invention, but that the inventionwill include all embodiments falling within the scope of the appendedclaims.

What is claimed is:
 1. A container, comprising: a container base; and aflexible film attached to the container base forming a container walland defining a packing region within the container, the container wallhaving at least one support column integrally formed therein.
 2. Thecontainer of claim 1, wherein the support column is a tubular supportcolumn.
 3. The container of claim 1, wherein the support columncomprises one or more overlapping folds.
 4. The container of claim 1,wherein the support column is oriented perpendicular to the containerbase.
 5. The container of claim 4, wherein the support column extendsfrom a bottom of the container to a top of the container.
 6. Thecontainer of claim 1, wherein the support column is a flattened supportcolumn.
 7. The container of claim 1, wherein the container wall is apolygon having at least three sides.
 8. The container of claim 7,wherein the support column is formed in a corner of the container wall.9. The container of claim 8, comprising support columns in each cornerof the container wall.
 10. The container of claim 7, wherein thecontainer wall has four wall portions and four corners.
 11. Thecontainer of claim 1, wherein the support column encloses a fluidmaterial, the support column being welded at opposing ends.
 12. Thecontainer of claim 11, wherein the support column encloses a gas. 13.The container of claim 1, wherein the flexible film comprises a materialselected from the group consisting of ethylene vinyl alcohol copolymer,polyamide, polyacrylonitrile, polyethylene terephthalate (PET),polyethylene, polypropylene, polyalkene (polyolefin), polylactic acid(PLA), cellophane, bioplastic-based film, metallized film, paper andcombinations thereof.
 14. The container of claim 11, wherein theflexible film comprises polypropylene and wherein the polypropylene isoriented polypropylene or cast polypropylene.
 15. The container of claim1, wherein the flexible film has a Gurley stiffness of 80 to 140 mg. 16.The container of claim 1, wherein the container base is a flexible filmmaterial.
 17. The container of claim 16, wherein a portion of theflexible film container base is configured to be a plane parallel to aportion of the container wall.
 18. The container of claim 1, furthercomprising a container cover attached to the container wall at anopposite end of the container as the container base.
 19. The containerof claim 18, wherein the container cover comprises a handle.
 20. Thecontainer of claim 18, wherein the container cover comprises a spout.21. The container of claim 18, wherein the container comprises a vent.22. The container of claim 18, wherein the container has a pressurizedinterior.
 23. The container of claim 1, wherein the container wall iscylindrical, triangular, rectangular or square.
 24. A manufacturingprocess, comprising: providing a web of flexible film; forming supportcolumns in the web of flexible film; and forming a container from theweb of flexible film containing the support columns.
 25. The process ofclaim 24, wherein forming support columns further comprises forming atleast two substantially parallel rows of support columns in the web offlexible film.
 26. The process of claim 24, wherein the support columnsare formed by ploughing and forming the web of flexible film.
 27. Theprocess of claim 24, wherein forming support columns further comprisesforming tubular support columns.
 28. The process of claim 27, furthercomprising enclosing a fluid material within the tubular supportcolumns.
 29. The process of claim 28, comprising enclosing air as thefluid material within the tubular support columns.
 30. The process ofclaim 28, further comprising enclosing the fluid material by welding thesupport columns at opposing ends.
 31. The process of claim 30, whereinthe welding is accomplished by ultrasonic welding.
 32. The process ofclaim 24, wherein forming support columns further comprises flatteningthe support columns against the web of flexible film.
 33. The process ofclaim 24, wherein forming a container further comprises transforming theweb of flexible film into a polygon to form a container wall andattaching a container base to the container wall.
 34. The process ofclaim 33, wherein attaching the container base comprises welding aflexible film container base to the container wall.
 35. The process ofclaim 33, further comprising attaching a container cover to thecontainer wall an opposite end of the container wall from the containerbase.
 36. The process of claim 33, wherein the transforming of the webinto a polygon comprises transforming the flexible film using a vacuumplenum to temporarily hold the container wall in position during weldingoperations.